Multi-Zone Powder Blender for Uniform Continuous Mixing
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Solution Overview
Problem
Existing systems for continuous processing of powder products lack flexibility in blending processes and often fail to achieve optimal blend uniformity and homogeneity, particularly when handling multiple ingredients.
Innovation Solution
A powder blender with at least two blending devices arranged successively along a longitudinal axis, actuated independently by different actuators, allowing for flexible blending processes that include high shear and low shear operations, and optionally incorporating dry agglomeration or granulation steps without wet granulation, to enhance blend uniformity and homogeneity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single blending device is used in the blending tube, then the device complexity is reduced, but the flexibility of blending processes and the quality of blend uniformity deteriorate
Solution Approach 1:
The blending tube is divided into multiple blending zones with at least two blending devices arranged successively along the longitudinal axis. Each blending device can be independently actuated by different actuators to perform specific blending functions (high shear, low shear, agglomeration, or granulation), thereby achieving process flexibility while maintaining manageable device complexity through modular segmentation.
2Manufacturing precision
If multiple blending devices are arranged successively along the longitudinal axis with independent actuators, then the flexibility of blending processes and blend uniformity are improved, but the device complexity increases
Solution Approach 1:
The blending tube is segmented into multiple blending zones with at least two blending devices arranged successively along the longitudinal axis. Each blending device can be independently actuated by different actuators to perform specific blending functions (high shear, low shear, agglomeration, or granulation), thereby achieving process flexibility while maintaining manageable device complexity through modular segmentation.
Solution Approach 2:
The multiple blending devices are designed to perform multiple blending functions including high shear blending, low shear blending, dry agglomeration, and dry granulation. This multi-functionality allows a single blending tube assembly to handle diverse powder blending requirements, improving blend uniformity while avoiding the need for separate specialized devices for each function.
3Object-generated harmful factors
If conventional blending systems are used, then the device complexity is maintained at acceptable levels, but segregation and product loss increase
Solution Approach 1:
The blending tube is segmented into multiple blending zones with at least two blending devices arranged successively along the longitudinal axis. Each blending device can be independently actuated by different actuators to perform specific blending functions (high shear, low shear, agglomeration, or granulation), thereby achieving process flexibility while maintaining manageable device complexity through modular segmentation.
Solution Approach 2:
The system enables dynamic adjustment of operational parameters including rotational speed, direction, and timing of each blending device independently. This parameter control allows optimization of blending intensity and duration for different powder properties, reducing segregation and product loss while maintaining acceptable device complexity through programmable control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides high flexibility and optimal blend uniformity and homogeneity, reducing segregation, dust, and product loss, while enabling continuous production of solid dosage forms like tablets and capsules, with adjustable operational parameters for various powder properties.
Implementation Method 1
allowing for flexible blending processes that include high shear and low shear operations
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
Powder blender for a system for continuous processing of powder products, the powder blender 38 comprising a horizontal blending tube 39, having at least one inlet 42, 44, 45 for powder products to be blended in the blending tube, and having at least one outlet 46 for discharging blended powder products, wherein in the blending tube at least two blending devices are arranged successively along a longitudinal axis of the blending tube, and wherein at least two actuators 56, 58 are provided for actuating the at least two blending devices differently from one another.